Additive manufacturing apparatus, method of manufacturing three-dimensional object, and method of teaching

Abstract

The present invention provides an unmanned layering molding device capable of achieving the removal of a molded object by more appropriately removing remaining material on a molding table, a manufacturing method of a three-dimensional molded object, and a teaching method. The layering molding device of the present invention includes a molding table, a chamber, a material layer forming device, a chuck device, a material recycling device, a transfer robot, a mobile robot, and a control device. The chuck device fixes a base plate to the molding table, the material recycling device includes a suction nozzle, the mobile robot is capable of moving the suction nozzle, and the control device alternately and repeatedly performs the raising of the molding table by a predetermined raising amount and the suction of remaining material powder while moving the suction nozzle by controlling the mobile robot according to teaching data. The teaching data includes the movement path and the posture of the suction nozzle corresponding to the shape of the molded object and the height of the molding table.

Description

Technical Field

[0001] This invention relates to a layered modeling device, a method for manufacturing three-dimensional models, and a teaching method. Background Technology

[0002] Various methods are known in the layering and molding of three-dimensional objects. For example, a layering and molding apparatus that implements powder bed fusion bonding places a base plate on a molding worktable located within a chamber. Material powder is supplied to the molding area to form a material layer. By irradiating a predetermined location on the material layer with a laser or electron beam, the material powder is sintered or melted to form a solidified layer. By repeatedly forming material layers and solidified layers, a solidified layer is layered on the base plate. As needed, cutting is performed during or after molding using a cutting mechanism, thereby manufacturing the desired three-dimensional object.

[0003] In powder bed molding, where material powders are layered and bonded together, not all the powder supplied to the molding area is cured. After molding, uncured powder may remain on the molded object, base plate, molding worktable, or its surroundings. Therefore, the remaining material needs to be removed when the molded object is removed from the chamber.

[0004] As disclosed in Patent Document 1, it is known to provide suction nozzles in a lamination molding apparatus for removing residual material. Before removing the molded object, the operator operates the suction nozzles to suction out the remaining material, thereby removing it. In such lamination molding apparatuses, there is a need to automatically remove the molded object from the chamber after molding. For example, in the case of secondary processing of the molded object, it is desirable to remove the molded object from the lamination molding apparatus and automatically perform a series of steps to send the removed molded object to a secondary processing device. When automatically removing the molded object from the chamber, it is necessary to automatically remove the residual material after molding. Patent Document 2 discloses a structure that uses suction nozzles to automatically remove residual material remaining after molding.

[0005] [Existing technical documents]

[0006] [Patent Literature]

[0007] [Patent Document 1] Japanese Patent No. 6132962

[0008] [Patent Document 2] Japanese Patent Application Publication No. 2002-205339 Summary of the Invention

[0009] [The problem the invention aims to solve]

[0010] In existing stacking molding devices, such as those shown in Patent Document 2, which automatically remove residual material by suction, it is often impossible to completely remove residual material remaining on the base plate, molding table, and periphery of the molding plate, including residual material that has entered the recesses or grooves formed on the molded object. When residual material remains on the molding table, it negatively impacts the high-precision positioning of the base plate or tray to be replaced in the next molding process and the reuse of material powder. Therefore, the molded object cannot be removed without manually removing the residual material, hindering the automation of molded object removal and handling.

[0011] The present invention was made in view of the above-mentioned circumstances, and its object is to provide an unmanned stacking modeling device, a method for manufacturing three-dimensional models, and a teaching method that enables the removal of models by more appropriately removing the remaining material on the modeling worktable.

[0012] [Technical means to solve the problem]

[0013] According to the present invention, the following invention is provided.

[0014] [1] A layered modeling device includes: a modeling worktable, a chamber, a material layer forming device, a chuck device, a material recycling device, a transport robot, a mobile robot, and a control device. In the layered modeling device, the modeling worktable is configured to move up and down via a worktable drive mechanism. The chamber covers an area on the modeling worktable where a model is formed, i.e., a modeling area. The material layer forming device supplies material powder to a base plate placed on the modeling area to form a material layer. The chuck device is disposed on the modeling worktable and configured to be able to detach and fix the base plate within the modeling area. The material recycling device includes a device capable of handling the material layer... The remaining material powder on the modeling worktable is sucked up by suction nozzles. The transport robot is configured to remove the base plate and the modeled object on the base plate from the chamber. The mobile robot is configured to move the suction nozzles. The control device alternately and repeatedly controls the worktable drive mechanism to raise the modeling worktable by a predetermined amount, and simultaneously controls the mobile robot to move the suction nozzles according to teaching data while sucking up the remaining material powder. The teaching data includes the movement path and posture of the suction nozzles corresponding to the shape of the modeled object and the height of the modeling worktable.

[0015] [2] The layered molding apparatus according to [1] includes a camera device configured to acquire an image of at least the area containing the base plate and the molding object, and the control device uses the image acquired by the camera device to determine whether there is any remaining material powder.

[0016] [3] The stacking molding device according to [1] or [2] includes a detection component, which is capable of detecting the proportion of the material powder in the material being sucked by the suction nozzle, and the control device determines whether there is any remaining material powder based on the proportion of the material powder.

[0017] [4] According to the stacking molding device described in [3], the detection component is a flow sensor.

[0018] [5] The layering molding apparatus according to any one of [1] to [4] includes: a powder holding wall surrounding the molding worktable and configured to hold the material powder on the molding worktable; and a material recovery bucket configured to contain the remaining material powder discharged to the outside of the powder holding wall, the material recovery device including a recovery mode and a suction mode as operating modes, the control device configured to switch the operating modes, the material recovery device being configured to: in the recovery mode, recover the material powder in the material recovery bucket and supply the material powder to the material layer forming apparatus after removing impurities; in the suction mode, move the suction nozzle using the mobile robot, suction the remaining material powder on the molding worktable using the suction nozzle, and remove impurities from the material powder.

[0019] [6] The stacking molding apparatus according to any one of [1] to [5], wherein the side of the chuck device is covered by a chuck cover, the chuck cover comprising an outer cover and an inner cover, the outer cover covering at least a portion of the side of the inner cover, the inner cover covering the side of the chuck device.

[0020] [7] The stacking molding apparatus according to any one of [1] to [6], wherein the chuck device fixes the base plate via a mounting plate.

[0021] [8] The stacking molding apparatus according to any one of [1] to [7], wherein the suction nozzle includes a suction part on the front end side, the suction part having a cylindrical shape formed by cutting off the end face of the front end side with an inclined surface, and an opening is provided on the inclined surface.

[0022] [9] The stacking molding apparatus according to any one of [1] to [8], wherein the transport robot is configured to transport the base plate into the cavity.

[0023]

[10] The stacking molding apparatus according to any one of [1] to [9], wherein the transport robot is configured to reverse the molding after removing the molding from the chamber.

[0024]

[11] A manufacturing method for a three-dimensional model includes: a placement process, a curing layer formation process, a suction process, and a removal process. In the placement process, a base plate is fixed by means of a chuck device disposed on a modeling worktable, and the base plate is placed on the modeling worktable in an area where a model is formed, i.e., a modeling area. In the curing layer formation process, a material layer formation process is repeated, in which material powder is supplied to the base plate to form a material layer, and a curing process is repeated, in which a curing layer is formed by irradiating a predetermined irradiation area of ​​the material layer with a laser or electron beam, thereby stacking the curing layer. In the suction process, the modeling worktable is alternately and repeatedly raised by a predetermined amount by means of a worktable drive mechanism, and the remaining material powder is suctioned while the suction nozzle is moved by a mobile robot according to teaching data. In the removal process, the base plate and the model formed on the base plate are removed from the chamber covering the modeling area by means of a transport robot. The teaching data includes the movement path and posture of the suction nozzle corresponding to the shape of the model and the height of the modeling worktable.

[0025]

[12] A teaching method for acquiring teaching data when suctioning residual material powder generated in the layering of a three-dimensional model using a suction nozzle, the teaching method comprising: a placement process, a modeling process, a recording process, and a lifting process, wherein in the placement process, a base plate is fixed by means of a chuck device disposed on a modeling worktable, and the base plate is placed on the modeling worktable in the area for forming the model, i.e., the modeling area, provided on the modeling worktable; and in the modeling process, a material layer forming process is performed repeatedly to supply material powder to the base plate to form a material layer, and a material layer forming process is performed repeatedly to supply material powder to the material layer. The curing process involves irradiating a designated area with a laser or electron beam to form a curing layer, thereby stacking the curing layer to create a three-dimensional object. In the recording process, while manually operating a mobile robot to move the suction nozzle, the remaining material powder on the modeling worktable is suctioned, and the position coordinates and posture of the suction nozzle are recorded. In the lifting process, the modeling worktable is raised by a predetermined amount. By repeatedly performing the recording process and the lifting process, teaching data containing the movement path and posture of the suction nozzle corresponding to the shape of the object and the height of the modeling worktable are obtained.

[0026] [The effects of the invention]

[0027] In the layered molding apparatus of the present invention, a suction nozzle capable of being moved by a mobile robot is provided. While the molding worktable is gradually raised, the suction nozzle moves according to taught data to remove remaining material. The taught data includes appropriate movement paths and postures of the suction nozzle corresponding to the shape of the molded object and the height of the molding worktable, thereby enabling more reliable and efficient removal of remaining material from the molding worktable. Since the removal of remaining material using the suction nozzle is automatic, unmanned removal of the molded object is achieved. Attached Figure Description

[0028] Figure 1 This is a schematic structural diagram of a layered molding device 100 according to an embodiment of the present invention.

[0029] Figure 2 This is a three-dimensional view of the material layer forming device 2 of the layered modeling device 100.

[0030] Figure 3 This is a perspective view from above the coating head 22 of the material layer forming apparatus 2.

[0031] Figure 4 This is a perspective view from below the coating head 22 of the material layer forming apparatus 2.

[0032] Figure 5 This is a perspective view showing the state in which the base plate 83 is fixed to the chuck device 5.

[0033] Figure 6 yes Figure 5 A cross-sectional view of line AA.

[0034] Figure 7 This is a perspective view showing the disassembled state of the tray 85, positioning plate 86, and shaft 87.

[0035] Figure 8 This is a perspective view showing the state in which the chuck cover 53 has been removed from the chuck assembly 5.

[0036] Figure 9a and Figure 9b This is a diagram showing the front end of the suction section 79a of the suction nozzle 79. Figure 9a This is a front view. Figure 9b This is the right-side view.

[0037] Figure 10 This is a diagram used to illustrate the suction pattern of the remaining material in the remaining material layer 81a using the suction nozzle 79.

[0038] Figure 11 This is a structural diagram of the control device 9 of the layered modeling device 100.

[0039] Figure 12 This is a flowchart of a method for manufacturing a three-dimensional model W using a layered modeling device 100.

[0040] Figure 13 This is a flowchart of a teaching method used to acquire teaching data.

[0041] Figure 14 This is a diagram used to illustrate the manufacturing method of a three-dimensional model W using the layered modeling device 100.

[0042] Figure 15 This diagram is used to illustrate the process of forming the cured layer.

[0043] Figure 16 This is a diagram used to illustrate the suction process.

[0044] [Explanation of Symbols]

[0045] 1: Chamber

[0046] 1a: Window

[0047] 2: Material layer forming device

[0048] 3: Irradiation device

[0049] 4: Styling workbench

[0050] 5: Chuck device

[0051] 6: Transport Robot

[0052] 7: Material recycling device

[0053] 8: Mobile Robots

[0054] 8a: Robotic Arm

[0055] 8b: Robotic arm

[0056] 8c: Torque sensor

[0057] 9: Control device

[0058] 10: Material Supply Unit

[0059] 11: Material Tank

[0060] 12: Main pipeline

[0061] 13: Intermediate pipe

[0062] 13a: Intermediate pipe outlet

[0063] 14: Opening and closing device

[0064] 17: Pollution prevention device

[0065] 17a: Frame

[0066] 17b: Diffusion component

[0067] 18: Camera device

[0068] 21: Base

[0069] 22: Coating head

[0070] 22a: Materials Storage Department

[0071] 22b: Material supply port

[0072] 22c: Material discharge outlet

[0073] 22fb: Blade

[0074] 22rb: Blade

[0075] 23: Coating head drive device

[0076] 41: Worktable drive mechanism

[0077] 42: Powder retaining wall

[0078] 51: Chuck base

[0079] 52: Clamping unit

[0080] 52a: First convex part

[0081] 52b: Second convex part

[0082] 52c: Contact recess

[0083] 52d: Ball bearing

[0084] 52e: Insertion hole

[0085] 53: Chuck Cover

[0086] 54: Outer cover

[0087] 54a: Outer covering portion

[0088] 54b: Upper surface portion

[0089] 55: Inner cover

[0090] 55a: Inner covering part

[0091] 55b: Flange portion

[0092] 70: Material recycling bin

[0093] 70a: Powder discharge section

[0094] 70b: Powder discharge section

[0095] 70c: Inclined groove guide

[0096] 70d: Inclined groove guide

[0097] 70e: Inclined groove

[0098] 71: Material recycling conveying device

[0099] 71a: Exhaust port

[0100] 71b: Suction port

[0101] 72: Switching valve

[0102] 73: Impurity Removal Device

[0103] 74: Suction device

[0104] 75: Switching valve

[0105] 76: Material Supply Barrel

[0106] 77: Material drying device

[0107] 78: Material supply conveying device

[0108] 78a: Exhaust port

[0109] 79: Suction Nozzle

[0110] 79a: Suction section

[0111] 79b: Opening

[0112] 81: Material layer

[0113] 81a: Remaining material layer

[0114] 82: Curing layer

[0115] 83: Base Plate

[0116] 84: Mounting plate

[0117] 85: Pallet

[0118] 86: Positioning plate

[0119] 86a: First opening

[0120] 86b: Second opening

[0121] 86c: Support foot

[0122] 86d: Mounting shaft

[0123] 87: Axis

[0124] 87a: Locking bolt

[0125] 87b: Locking part

[0126] 87c: Concave

[0127] 90a: CAD device

[0128] 90b: CAM device

[0129] 90c: Image processing device

[0130] 91: Numerical Control Department

[0131] 91a: Storage Unit

[0132] 91b: Arithmetic Unit

[0133] 91c: Memory

[0134] 92: Operation Door Control Department

[0135] 93: Material layer formation control section

[0136] 94: Irradiation Control Department

[0137] 95: Workbench Control Department

[0138] 96: Chuck Control Unit

[0139] 97: Control Department of the Transport Robot

[0140] 98: Materials Supply / Recycling Control Department

[0141] 99: Mobile Robot Control Department

[0142] 100: Layered Design Installation

[0143] B: Laser

[0144] R: Design Area

[0145] W: Three-dimensional model Detailed Implementation

[0146] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The features shown in the embodiments described below can be combined with each other. Furthermore, the invention is independent of each feature.

[0147] 1. Layered modeling device 100

[0148] Figure 1 This is a schematic structural diagram of the layered modeling apparatus 100 according to this embodiment. The layered modeling apparatus 100 includes: a chamber 1, a material layer forming apparatus 2, an irradiation apparatus 3, a modeling worktable 4, a chuck apparatus 5, a transfer robot 6, a material recycling apparatus 7, a mobile robot 8, a camera apparatus 18, and a control apparatus 9. In the modeling area R provided on the modeling worktable 4 disposed in the chamber 1, the desired three-dimensional model W can be formed by repeatedly forming material layers 81 and curing layers 82.

[0149] 1.1. Chamber 1

[0150] Chamber 1 covers the area where the desired three-dimensional shape W is formed, namely the shaping area R. The interior of chamber 1 is filled with an inert gas of a specified concentration supplied by an inert gas supply device (not shown). In this specification, inert gas refers to a gas that does not substantially react with material layer 81 or cured layer 82, and is selected depending on the type of material; for example, nitrogen, argon, or helium can be used. The inert gas containing fumes generated during the formation of cured layer 82 is discharged from chamber 1, and after fumes are removed in a fume collector (not shown), it is supplied back to chamber 1 for reuse. The fume collector is, for example, an electrostatic precipitator or a filter.

[0151] On the upper surface of chamber 1, a window 1a is provided, serving as a transmission window for laser B. Window 1a is formed of a material that allows laser B to pass through. Specifically, the material of window 1a is selected from quartz glass, borosilicate glass, or crystals of germanium, silicon, zinc selenide, or potassium bromide, depending on the type of laser B. For example, in the case where laser B is a fiber laser or a yttrium aluminum garnet (YAG) laser, window 1a may comprise quartz glass.

[0152] Additionally, a contamination prevention device 17 is provided on the upper surface of chamber 1 to cover window 1a. The contamination prevention device 17 includes a cylindrical frame 17a and a cylindrical diffusion member 17b disposed within the frame 17a. Clean inert gas supplied to the space between the frame 17a and the diffusion member 17b passes through fine holes formed on the wall of the diffusion member 17b and fills the interior of the diffusion member 17b, then passes through an opening on the bottom surface of the frame 17a and is ejected downwards. This structure prevents smoke from adhering to window 1a, thereby removing smoke from the irradiation path of laser B.

[0153] Additionally, a working door (not shown) controlled by a control device 9 is provided in chamber 1. When the base plate 83 is moved into chamber 1, or when the base plate 83 and the model W are removed from chamber 1, the working door opens, and the transport robot 6 enters and exits chamber 1 to perform loading and unloading operations. When loading and unloading operations are not performed, especially during modeling, the working door is closed.

[0154] 1.2. Material layer forming apparatus 2

[0155] The material layer forming apparatus 2 supplies material powder to the base plate 83 placed in the molding area R to form a material layer 81. For example... Figures 1 to 4 As shown, the material layer forming apparatus 2 is disposed inside the chamber 1, and includes a base 21 and a coating head 22 disposed on the base 21. The coating head 22 is configured to reciprocate in a horizontal single-axis direction via a coating head drive device 23.

[0156] like Figure 3 and Figure 4 As shown, the coating head 22 includes a material receiving section 22a, a material supply port 22b, and a material discharge port 22c. The material supply port 22b is located on the upper surface of the material receiving section 22a and is rectangular in shape, extending along the length of the material receiving section 22a, serving as a receiving port for material powder supplied from the material supply unit 10 to the material receiving section 22a. The material discharge port 22c is located on the bottom surface of the material receiving section 22a, discharging the material powder from within the material receiving section 22a. The material discharge port 22c has a slit shape extending along the length of the material receiving section 22a. Flat blades 22fb and 22rb are provided on both sides of the coating head 22. The blades 22fb and 22rb flatten the material powder discharged from the material discharge port 22c, forming a material layer 81.

[0157] 1.3. Irradiation device 3

[0158] like Figure 1As shown, the irradiation device 3 is positioned above the chamber 1. The irradiation device 3 irradiates the irradiation area of ​​the material layer 81 formed within the molding area R with laser B, causing the material powder to melt or sinter and solidify, forming a solidified layer 82. Laser B can be any laser capable of sintering or melting the material powder, such as a fiber laser, CO2 laser, or YAG laser. Alternatively, the irradiation device 3 can be configured to use an electron beam instead of laser B to solidify the material layer 81.

[0159] 1.4. Modeling Workbench 4

[0160] A modeling worktable 4 is disposed within the chamber 1, and a modeling area R is provided on its upper surface. The modeling worktable 4 is configured to move up and down via a worktable drive mechanism 41. In this embodiment, the worktable drive mechanism 41 is configured using a motor as the drive source. Furthermore, the structure of the worktable drive mechanism 41 is not limited to the example of this embodiment; it can be of other forms as long as it enables the modeling worktable 4 to move in the vertical direction.

[0161] 1.5. Chuck assembly 5

[0162] The chuck device 5 is disposed on the molding worktable 4 and is configured to allow the base plate 83 to be freely loaded and unloaded and fixed within the molding area R. The base plate 83 is held and fixed by the chuck device 5, and is placed within the molding area R.

[0163] The base plate 83 can be directly fixed by the chuck device 5, or it can be fixed by other components such as the mounting plate 84. In this embodiment, for example... Figure 1 , Figure 5 ,and Figure 6 As shown, the base plate 83 is detachably fixed by the chuck device 5 via the mounting plate 84 and the tray 85. Specifically, a shaft 87 is mounted on the bottom surface of the tray 85 in a downward-facing manner, and the chuck device 5 holds the shaft 87, thereby detachably fixing the tray 85. Furthermore, the mounting plate 84 is fixed to the tray 85 using bolts or other fixing components, and the base plate 83 is fixed to the mounting plate 84 using bolts or other fixing components. That is, the chuck device 5, tray 85, mounting plate 84, and base plate 83 are arranged sequentially from the bottom, and a three-dimensional object W is formed on the upper surface of the base plate 83.

[0164] like Figures 6 to 8 As shown, the chuck device 5 of this embodiment includes a chuck base 51 disposed on the molding worktable 4 and a clamping unit 52 disposed on the chuck base 51.

[0165] The chuck base 51 is used to fix the chuck device 5 to the molding worktable 4. In this embodiment, the four corners of the chuck base 51, which is quadrilateral in shape when viewed from above, are fixed to the molding worktable 4 by fixing components such as bolts.

[0166] The clamping unit 52 has a generally bottomed cylindrical shape. On the upper surface of the clamping unit 52, a plurality of (four in one example) first protrusions 52a and second protrusions 52b are respectively provided in a concentric circle shape when viewed from above. Furthermore, a plurality of (four in one example) abutment recesses 52c are provided, radially formed from the center when viewed from above. Additionally, as... Figure 6 As shown, inside the clamping unit 52, a plurality of balls 52d are arranged at equal intervals along the circumference of the shaft 87 as locking members to lock the shaft 87.

[0167] like Figure 6 and Figure 7 As shown, shaft 87 includes a locking bolt 87a and a locking portion 87b disposed on the outside of the locking bolt 87a. A threaded portion is formed on the upper end of the locking bolt 87a. By screwing the threaded portion into a threaded hole formed on the bottom surface of the tray 85, the locking bolt 87a is installed on the tray 85. In addition, the lower end of the locking bolt 87a is inserted into the insertion hole 52e of the clamping unit 52, and the ball 52d of the clamping unit 52 engages with the recess 87c of the locking portion 87b, thereby locking the shaft 87. Thus, the tray 85 is fixed to the chuck device 5.

[0168] Furthermore, in this embodiment, a positioning plate 86 is clamped between the tray 85 and the clamping unit 52. The positioning plate 86 is fixed to the bottom surface of the tray 85 using bolts or other fixing components. The positioning plate 86 is provided with a plurality of (four in one example) first openings 86a and second openings 86b. The first openings 86a and second openings 86b are positioned to overlap with the first protrusions 52a and second protrusions 52b of the clamping unit 52 when viewed from above. The positioning plate 86 is positioned horizontally by the first protrusion 52a penetrating to the first opening 86a and the second protrusion 52b penetrating to the second opening 86b.

[0169] Additionally, multiple (four in one example) support feet 86c are mounted on the lower surface of the positioning plate 86 using a mounting shaft 86d. The support feet 86c are mounted at a position overlapping the abutment recess 52c when viewed from above. The positioning plate 86 is positioned vertically by the bottom surface of the support feet 86c abutting against the abutment recess 52c. By mounting the positioning plate 86 onto the tray 85, when the tray 85 is secured using the chuck device 5, the mounting plate 84 and the base plate 83 fixed to the tray 85 can be precisely positioned in predetermined positions in both the horizontal and vertical directions.

[0170] In this embodiment, the base plate 83 is fixed to the chuck assembly 5 via other components (mounting plate 84 and tray 85). In this structure, mounting portions such as threaded holes for mounting the shaft 87 or positioning plate 86 can be formed on the other components. Furthermore, these other components can be partially or completely removed from the base plate 83 and reused after molding. Therefore, it is not necessary to provide mounting portions on the base plate 83 according to the shape of the chuck assembly 5, thus enabling the base plate 83 to be manufactured more cost-effectively.

[0171] like Figure 5 and Figure 6 As shown, in this embodiment, the side of the chuck assembly 5 is covered by a chuck cover 53. The chuck cover 53 includes an outer cover 54 and an inner cover 55. The outer cover 54 covers at least a portion of the side of the inner cover 55, and the inner cover 55 covers the side of the chuck assembly 5. Metal or resin, etc., can be used as the raw material for the chuck cover 53.

[0172] Specifically, such as Figure 6 and Figure 8 As shown, the inner cover 55 includes a cylindrical inner covering portion 55a and a flange portion 55b extending radially outward from the lower end of the inner covering portion 55a. The inner covering portion 55a covers the side of the clamping unit 52 of the chuck assembly 5. The inner cover 55 is fixed to the chuck base 51 in the flange portion 55b. The outer cover 54 includes a cylindrical outer covering portion 54a and an upper surface portion 54b extending radially inward from the upper end of the outer covering portion 54a. The outer covering portion 54a covers a portion of the upper side of the side of the inner covering portion 55a. The outer cover 54 is fixed to the tray 85 in the upper surface portion 54b, with the upper surface of the upper surface portion 54b in contact with the bottom surface of the tray 85. Furthermore, the outer cover 54 and the inner cover 55 are arranged coaxially with the outer covering portion 54a and the inner covering portion 55a. With this structure, when the chuck device 5 is released from fixing the base plate 83 during or after the shaping process, residual material can be prevented from entering the interior of the chuck device 5, especially the clamping unit 52.

[0173] In addition, such as Figure 6 As shown, a gap G is provided between the outer cover 54 and the inner cover 55. Specifically, the outer cover 54 and the inner cover 55 are designed to satisfy the condition D1 > D2, and the gap G is provided accordingly. Furthermore, the gap G is preferably provided such that the distance between the inner surface of the outer cover 54a and the outer surface of the inner cover 55a (in this embodiment, (D1-D2) / 2) is 1 mm to 10 mm. In this structure, the path of residual material or other powder falling from the base plate 83 to the inside of the chuck cover 53 is curved, thus more effectively preventing powder intrusion.

[0174] Furthermore, the structure of the chuck cover 53 is not limited to the example of this embodiment. For example, the inner covering portion 55a and the outer covering portion 54a may also be cylindrical. Figures 6 to 8 The chuck device 5 of the embodiment shown can reduce the possibility of the molding process being unable to continue due to the remaining material powder intruding into the clamping unit 52, regardless of the process by which the transfer robot 6 sucks up and removes the remaining material powder, thus supporting unmanned operation of continuous molding.

[0175] 1.6. Transport Robot 6

[0176] The transport robot 6 is configured to remove the base plate 83 and the molded object W molded on the base plate 83 from the chamber 1. In this embodiment, after molding is completed, the ball bearing 52d of the clamping unit 52 engages / disengages from the recess 87c, thereby releasing the chuck device 5 from fixing the pallet 85. In this state, the transport robot 6 grips a predetermined part of the pallet 85, or inserts a support rod into a support hole (not shown) provided on the side of the pallet 85 and lifts it, thereby removing the base plate 83 and the molded object W from the chamber 1 via the mounting plate 84, the pallet 85, the shaft 87, the outer cover 54, and the operating door.

[0177] Alternatively, the transport robot 6 can be configured to move the model W to a predetermined position and reverse its vertical direction after removing it from the chamber 1. By reversing the model W, any remaining material attached to the model W or the base plate 83 can fall off and be removed. At this time, the reversed model W can be placed on a finishing device (not shown) installed on the outside of the chamber 1 for automatic or manual finishing removal of the remaining material. Examples of finishing removal methods include: using a suction nozzle to suction the material powder, vibrating the model W to make the material powder fall off, or transporting the model W to a suction chamber (not shown) outside the chamber 1 for powder suction removal.

[0178] When the model W is being processed, the transfer robot 6 moves the base plate 83 and the model W taken out from the chamber 1 to the secondary processing device (not shown).

[0179] Furthermore, the transport robot 6 of this embodiment is also used to move the base plate 83 into the chamber 1 before the molding process begins. Specifically, the base plate 83, mounting plate 84, tray 85, shaft 87, and outer cover 54 are integrated into a base plate assembly in a storage container (not shown) located outside the chamber 1. The transport robot 6 moves the base plate assembly into the chamber 1 by gripping a designated part of the tray 85 or by inserting a support rod into a support hole provided on the side of the tray 85 and lifting it. The lower end of the shaft 87 is inserted into the clamping unit 52. The tray 85 is fixed by the chuck device 5 by engaging the ball bearing 52d with the recess 87c of the inserted shaft 87.

[0180] 1.7. Material Powder Supply / Recovery System

[0181] Next, the material powder supply / recovery system, including the material recovery device 7, will be described. For example... Figure 1 As shown, a material supply unit 10 is provided near the wall of chamber 1. The material supply unit 10 includes a material tank 11, a main pipe 12, and an intermediate pipe 13. The material tank 11 contains novel material powder, which is supplied to the intermediate pipe 13 through the main pipe 12.

[0182] The intermediate conduit 13 is movable in the vertical direction and is configured to discharge material powder from the intermediate conduit outlet 13a. In this embodiment, the intermediate conduit outlet 13a is a rectangular shape extending in approximately the same direction as the material supply port 22b of the coating head 22. Furthermore, the intermediate conduit outlet 13a is configured to be openable and closed by the opener 14. The intermediate conduit outlet 13a is normally closed by the opener 14. When replenishing material powder, the coating head 22 moves to directly below the intermediate conduit 13, and the intermediate conduit 13 moves to a position where the intermediate conduit outlet 13a is lower than the upper end of the material receiving section 22a. In this state, the opener 14 is opened, and material powder is replenished.

[0183] In this embodiment, a powder holding wall 42 is provided around the molding worktable 4. The powder material is held on the molding worktable 4 by the powder holding wall 42. In addition, a material recycling bin 70 is provided, which is configured to collect the remaining material discharged to the outside of the powder holding wall 42.

[0184] At least one powder discharge section 70b, communicating with a material recovery bin 70, is provided on the base 21 of the material layer forming apparatus 2. Residual material or impurities extruded by the moving coating head 22 are discharged from the powder discharge section 70b, guided by the chute guide 70d to the chute 70e, and collected in the material recovery bin 70. Furthermore, the powder discharge section 70b may also be configured to be openable / closeable by an opener / closer (not shown). Alternatively, a powder discharge section 70a, capable of discharging material powder from the inner side of the powder holding wall 42, may be provided on the lower side of the powder holding wall 42. After the layering molding is completed, the molding table 4 is lowered, thereby discharging a portion of uncured material powder or impurities such as cutting chips from the powder discharge section 70a. In this case, the material powder discharged from the powder discharge section 70a is guided by the chute guide 70c to the chute 70e and collected in the material recovery bin 70.

[0185] like Figure 1 As shown, the material recovery apparatus 7 of this embodiment includes: a material recovery conveying device 71, an impurity removal device 73, a suction device 74, a material supply tank 76, a material drying device 77, a material supply conveying device 78, and a suction nozzle 79. The suction port 71b of the material recovery conveying device 71 is connected to the material recovery tank 70 via a switching valve 72 and piping, etc. Material powder containing impurities in the material recovery tank 70 is conveyed to the impurity removal device 73 by the material recovery conveying device 71. Examples of impurities include sputtering deposition generated during irradiation, or machining chips generated during cutting. The impurity removal device 73 removes impurities from the material powder conveyed from the material recovery conveying device 71. The material powder with impurities removed is contained in the material supply tank 76. The material drying device 77 dries the material powder in the material supply tank 76. The material powder dried by the material drying device 77 is supplied to the main pipeline 12 and reused through the material supply conveying device 78 connected to the upper part of the main pipeline 12.

[0186] Both the material recycling conveying device 71 and the material supply conveying device 78 have internal cyclone filters. The exhaust ports 71a and 78a of the filters are connected to the suction device 74 via a switching valve 75 and piping. The suction device 74 has suction power capable of simultaneously suctioning both gas and solids, and is configured, for example, using a cleaner. When the suction device 74 simultaneously suctions solids such as material powder or impurities and gas, the filter uses the difference in specific gravity to separate the solids from the airflow and cause them to fall. Thus, the solids are conveyed, and the gas is drawn from the exhaust ports 71a and 78a to the suction device 74. Furthermore, one suction device 74 can be switched between the material recycling conveying device 71 and the material supply conveying device 78 via the switching valve 75, or one suction device 74 can be independently connected to each of the material recycling conveying device 71 and the material supply conveying device 78.

[0187] The suction nozzle 79 is configured to suction the remaining material powder on the molding worktable 4. The suction nozzle 79 is housed in a storage part (not shown) outside the chamber 1, and is moved into the chamber 1 by the mobile robot 8 during suction.

[0188] In addition, to clean the cavity 1, the suction nozzle 79 can be used to suction out any remaining material or debris scattered in the area outside the molding worktable 4 (in other words, the outside of the molding area R) within the cavity 1. If molding is performed with remaining material or the like in the area outside the molding area R, it may cause abnormal operation or malfunction of the automatic operation of the stacking molding device 100. This situation can be avoided by using the suction nozzle 79 to suction out the remaining material or the like in the area outside the molding area R.

[0189] In this embodiment, the suction nozzle 79 is connected to the suction port 71b of the material recycling conveying device 71 via a switching valve 72 and piping. For example, the suction nozzle 79 can be installed at one end of a flexible hose, and the other end of the hose can be connected to the suction port 71b via the switching valve 72. The material powder sucked from the suction nozzle 79 is then subjected to impurity removal and drying processes using the same method described above, and then supplied to the main pipeline 12.

[0190] The stacking molding apparatus 100 of this embodiment includes a detection component (not shown) capable of detecting the proportion of material powder in a material being suctioned by a suction nozzle 79. The proportion of material powder in the material being suctioned can be, for example, the volumetric flow rate ratio, the mass flow rate ratio, or the area ratio within a defined detection region. In this embodiment, a flow sensor is installed inside the suction nozzle 79 or the hose on which the suction nozzle 79 is installed as the detection component. As an example, the flow sensor is configured to detect the volumetric flow rate of the powder in the material being suctioned. Specifically, the flow sensor emits microwaves at a predetermined position inside the suction nozzle 79 or the hose and receives their reflected waves. The frequency and amplitude of the reflected waves change according to the amount of powder in the material being suctioned passing through the predetermined position, and therefore the volumetric flow rate of the material powder in the material being suctioned can be detected based on these changes to obtain the volumetric flow rate ratio of the material powder. The detection result obtained by the detection component is output to the control device 9. Furthermore, the detection component can be configured to directly detect the proportion of material powder in the aspirated material, or it can be configured to indirectly detect the proportion of material powder. In the case of indirect detection, for example, the proportion of gas in the aspirated material can also be detected, and the proportion of material powder can be obtained based on the detection result.

[0191] Figure 9a and Figure 9b This is a diagram showing the front end of the suction section 79a of the suction nozzle 79. Figure 9a This is a front view. Figure 9b This is the right-side view. The suction nozzle 79 of this embodiment includes a suction section 79a on its front end side. Additionally, in... Figure 9a and Figure 9b The illustration is omitted, but a gripping part that the mobile robot 8 can hold is provided on the base end side of the suction nozzle 79. The suction part 79a has a cylindrical shape formed by cutting off the end face of the front end with an inclined surface, and an opening 79b is provided on the inclined surface. The remaining material is sucked out from the opening 79b.

[0192] In this structure, such as Figure 10 As shown, when the suction nozzle 79 is brought close to the layer containing the remaining material (remaining material layer 81a) and a portion of the opening 79b is embedded in the remaining material layer 81a, the material powder is drawn from the opening 79b. At this time, the gas is drawn from the portion of the opening 79b that is not embedded in the remaining material layer 81a. By drawing both the material powder and the gas simultaneously, situations where an excessive proportion of solids in the material being drawn reduces the suction force or causes blockage inside the suction nozzle 79 and the hose can be avoided.

[0193] The material recovery device 7 of this embodiment includes a recovery mode and a suction mode as operating modes, which are switched by the material supply / recovery control unit 98 of the control device 9 (described later). In the recovery mode, the material recovery device 7 recovers the material powder in the material recovery bin 70 and supplies the material powder to the material layer forming apparatus 2 after removing impurities. On the other hand, in the suction mode, the material recovery device 7 uses the mobile robot 8 to move the suction nozzle 79 and uses the suction nozzle 79 to suction the remaining material powder on the molding worktable 4. In this embodiment, the material supply / recovery control unit 98 switches the switching valve 72, thereby switching between the recovery mode where the material powder is transported from the material recovery bin 70 by the material recovery conveying device 71 and the suction mode where the transport source is the suction nozzle 79.

[0194] 1.8. Mobile Robot 8

[0195] The mobile robot 8 is configured to move the suction nozzle 79. In this embodiment, the mobile robot 8 can grasp the suction nozzle 79 stored in the storage section outside the chamber 1 and move it from the work door into the chamber 1, placing the suction nozzle 79 at any position within the chamber 1. Furthermore, the mobile robot 8 can change the posture (orientation and angle) of the suction nozzle 79 relative to the shaped object W by tilting or other operations. In addition, the mobile robot 8 can... Figure 1 As shown, it can be separated from the transport robot 6, or it can be mounted on the transport robot 6.

[0196] The mobile robot 8 is controlled by the mobile robot control unit 99 of the control device 9 (described later) to move the suction nozzle 79. This control is performed according to pre-acquired teaching data. The teaching data includes the movement path and posture of the suction nozzle 79 corresponding to the shape of the modeling object W and the height of the modeling worktable 4.

[0197] like Figure 1 As shown, the mobile robot 8 of this embodiment includes a robotic arm 8a and a robotic hand 8b disposed at the front end of the robotic arm 8a and holding a suction nozzle 79, and is driven by a drive device (not shown). In addition, the mobile robot 8 includes a torque sensor 8c capable of detecting the torque acting on the joints of the robotic arm 8a. The torque detection result obtained by the torque sensor 8c is output to the control device 9.

[0198] 1.9. Camera device 18

[0199] The imaging device 18 is configured to acquire images of at least the area (imaging area) including the base plate 83 and the object W. The imaging device 18 is, for example, a charge-coupled device (CCD) camera or a complementary metal-oxide-semiconductor (CMOS) camera. The acquired images are output to the image processing device 90c, described later.

[0200] like Figure 1 As shown, the camera device 18 is disposed within the chamber 1. Its placement within the chamber 1 is not particularly limited, as long as it allows for capturing the image area and does not obstruct the movement of the coating head 22 or the irradiation of the laser B during molding. For example, the camera device 18 can be placed near the ceiling of the chamber 1 to capture the image area from above, or it can be placed near the side wall of the chamber 1 to capture the image area from the side. Furthermore, the camera device 18 can be configured to move within the chamber 1 to change the image area and shooting direction; multiple camera devices 18 can also be disposed to capture images in multiple image areas and shooting directions. Additionally, when the suction nozzle 79 is used to suction the remaining material in the area outside the molding area R as described above, that area can also be included in the image area.

[0201] The acquired images are used to determine whether the suction nozzle 79 has completed suction of the remaining material based on the presence or absence of remaining material in the imaging area. For this purpose, the imaging device 18 acquires at least two images: an image of the imaging area in which the base plate 83 and the completed model W are fixed in the modeling area R by the chuck device 5 and there is no remaining material (cleaning image), and an image of the imaging area when suction is determined to be complete (determination image). By analyzing the difference between the cleaning image and the determination image using the image processing device 90c, it is possible to determine whether the suction nozzle 79 has completed suction of the remaining material. Furthermore, the cleaning image can be acquired during a trial modeling process conducted as a preliminary investigation for manufacturing the model W, by taking a picture after the model W has been shaped and the remaining material in the chamber 1 has been removed.

[0202] 1.10. Control Device 9

[0203] like Figure 11As shown, the control system of the stacked modeling device 100 includes: a Computer-Aided Design (CAD) device 90a, a Computer-Aided Manufacturing (CAM) device 90b, an image processing device 90c, and a control device 9. These devices are constructed by arbitrarily combining hardware and software such as a Central Processing Unit (CPU), Random Access Memory (RAM), Read Only Memory (ROM), auxiliary storage devices, and input / output interfaces. Hereinafter, the description will focus on the control actions performed by the control system that are most closely related to the present invention.

[0204] CAD device 90a creates three-dimensional shape data (CAD data) that defines the shape and dimensions of a symmetrical three-dimensional model W. CAM device 90b creates a project file based on the CAD data, specifying instructions for the layered modeling device 100. CAM device 90b transmits the project file to control device 9 via a communication line or storage medium.

[0205] The image processing apparatus 90c analyzes the cleaning image and the judgment image acquired by the imaging device 18. In one example, after appropriately preprocessing the image, the image processing apparatus 90c performs binarization processing to identify the areas in the image where material powder is present and other areas. The analysis data marked by the binarization processing is sent to the control device 9. The binarization processing is preferably performed in pixel units of image data or in unit units containing multiple pixels.

[0206] The control device 9 controls the constituent elements of the layered modeling device 100, including the material layer forming device 2, the irradiation device 3, the modeling worktable 4, the chuck device 5, the transport robot 6, the material recycling device 7, and the mobile robot 8, to perform layered modeling according to the project documents. The control device 9 includes a numerical control unit 91 and control units 92, 93, 94, 95, 96, 97, 98, and 99 for the constituent elements of the layered modeling device 100.

[0207] The numerical control unit 91 outputs motion commands for the constituent elements of the stacked modeling device 100 to control units 92, 93, 94, 95, 96, 97, and 98 according to the project file created by the CAM device 90b. These control units include a storage unit 91a, a calculation unit 91b, and a memory 91c. The storage unit 91a stores the project file obtained from the CAM device 90b and teaching data used to control the mobile robot 8. The calculation unit 91b performs numerical control calculations for the constituent elements of the stacked modeling device 100 according to the project file. Furthermore, the calculation unit 91b outputs motion commands based on the teaching data to the mobile robot control unit 99. The memory 91c temporarily stores numerical values ​​or data during the calculations performed by the calculation unit 91b.

[0208] The control units 92, 93, 94, 95, 96, 97, 98, and 99 of the constituent elements of the layering molding apparatus 100 control the operation of each constituent element based on action commands from the numerical control unit 91. Specifically, the work door control unit 92 controls the work door to open / close it at appropriate times. The material layer forming control unit 93 controls the coating head drive device 23 to reciprocate the coating head 22 along a horizontal single axis. The irradiation control unit 94 controls the irradiation device 3 to irradiate a predetermined position within the irradiation area under predetermined conditions using laser B.

[0209] The worktable control unit 95 controls the worktable drive mechanism 41, causing the modeling worktable 4 to move vertically and be positioned at a predetermined location. The chuck control unit 96 controls the clamping unit 52 of the chuck device 5 to switch between fixing and releasing the base plate 83.

[0210] The transfer robot control unit 97 controls the transfer robot 6 to move the base plate 83 into the chamber 1, remove the base plate 83 and the model W from the chamber 1, and, as needed, reverse the model W after it is removed from the chamber 1 and move it to the secondary processing device.

[0211] The material supply / recycling control unit 98 controls the material recycling device 7 and the material supply unit 10. It also switches the operating mode of the material recycling device 7.

[0212] The mobile robot control unit 99 controls the mobile robot 8 to grasp the suction nozzle 79 and move it into the chamber 1. Furthermore, the mobile robot control unit 99 controls the mobile robot 8 to move the suction nozzle 79 within the chamber 1 while simultaneously suctioning out remaining material. Additionally, when the mobile robot 8 is mounted on the transport robot 6, the transport robot control unit 97 can also perform the functions of the mobile robot control unit 99.

[0213] In addition to the aforementioned structure, the stacking molding apparatus 100 may also include a machining device (not shown) within the chamber 1 for machining the cured layer 82 and the molded object W as needed, such as cutting. The machining device may be configured such that a tool for cutting (e.g., an end mill) is mounted on a machining head, allowing the machining head to move appropriately in both the horizontal and vertical directions to machine the cured layer 82 or the molded object W. Alternatively, the tool may be configured to rotate via a spindle mounted on the machining head.

[0214] 2. Manufacturing method of three-dimensional model W

[0215] Next, refer to Figure 12 The manufacturing method of a three-dimensional model W using the layered modeling apparatus 100 of this embodiment will be described. The manufacturing method of this embodiment includes: a placement step S1-1, a material supply step S1-2, a curing layer formation step S1-3, a material recycling step S1-4, a suction step S1-5, and a removal step S1-6.

[0216] 2.1. Loading process S1-1

[0217] In the placement process S1-1, the base plate 83 is placed on the molding area R of the molding worktable 4. Specifically, firstly, the work door control unit 92 controls the work door to open. Additionally, the transfer robot control unit 97 controls the transfer robot 6 to move the base plate assembly from the storage container outside the chamber 1 into the chamber 1. The transfer robot 6 moves the base plate assembly into the chamber 1 through the open work door and inserts the lower end of the shaft 87 into the insertion hole 52e of the clamping unit 52. In this state, the chuck control unit 96 controls the clamping unit 52 of the chuck device 5 to engage the ball bearing 52d with the locking part 87b of the shaft 87. Thus, as... Figure 14 As shown, the base plate 83 is placed in the shaping area R in a state where it is easily fixed to the chuck assembly 5. In addition, the sides of the chuck assembly 5 are covered by a chuck cover 53, which includes an outer cover 54 and an inner cover 55.

[0218] After the base plate 83 is placed, the transport robot control unit 97 controls the transport robot 6 to retreat outside the chamber 1, and the work door control unit 92 closes the work door. Then, inert gas is supplied to and fills the chamber 1 from the inert gas supply device. This creates a state where molding can begin.

[0219] 2.2. Material supply process S1-2

[0220] In the material supply process S1-2, material powder is supplied to and contained in the material receiving section 22a of the material layer forming apparatus 2. Specifically, the material layer forming control unit 93 controls the coating head drive device 23 to move the coating head 22 directly below the intermediate pipe 13. In this state, the material supply / recovery control unit 98 controls the material supply unit 10 to open the switch 14 and supply material powder into the material receiving section 22a. When a sufficient amount of material powder has been supplied, the material supply / recovery control unit 98 closes the switch 14 to stop the supply. Thereafter, the material layer forming control unit 93 controls the coating head drive device 23 to move the coating head 22 to the molding area R. Furthermore, the material supply process S1-2 is performed multiple times during the period from the start to the completion of molding to replenish material powder to the material receiving section 22a.

[0221] 2.3. Curing layer formation process S1-3

[0222] Next, the curing layer formation process S1-3 is performed. In the curing layer formation process S1-3, the curing layer 82 is stacked by repeatedly performing the material layer formation process S1-3-1, which forms the material layer 81 by supplying material powder to the base plate 83, and the curing process S1-3-2, which forms the curing layer 82 by irradiating a specified irradiation area of ​​the material layer 81 with laser B.

[0223] Specifically, firstly, the worktable control unit 95 controls the worktable drive mechanism 41 to position the molding worktable 4 at a predetermined height. In this state, the material layer forming control unit 93 controls the coating head drive device 23 to move the coating head 22 from... Figure 14 The material moves from the left to the right. This forms a first material layer 81 on the base plate 83. Next, the irradiation control unit 94 controls the irradiation device 3 to irradiate a predetermined irradiation area of ​​the first material layer 81 with laser B or an electron beam. Thus, as... Figure 15 As shown, the first material layer 81 is cured to obtain the first cured layer 82.

[0224] Next, the second material layer forming process S1-3-1 is performed. After the first cured layer 82 is formed, the worktable control unit 95 controls the worktable drive mechanism 41 to lower the height of the molding worktable 4 by an amount equivalent to one layer of material layer 81. In this state, the material layer forming control unit 93 controls the coating head drive device 23 to move the coating head 22 from... Figure 15The right side of the shaping area R is moved to the left side. This forms a second material layer 81, covering the first cured layer 82. Then, a second curing process S1-3-2 is performed. Using the same method as described above, the second material layer 81 is cured by irradiating a designated irradiation area with laser B, thus obtaining the second cured layer 82.

[0225] The material layer formation process S1-3-1 and the curing process S1-3-2 are repeated repeatedly to stack multiple cured layers 82 until the desired three-dimensional object W is obtained. Adjacent cured layers 82 are firmly bonded to each other. In addition, during or after molding, cutting processes using machining equipment are performed as needed.

[0226] 2.4. Material recycling process S1-4

[0227] The material recycling process S1-4 is performed in parallel with the curing layer formation process S1-3. In the material recycling process S1-4, the material recycling device 7 operates in recycling mode. Specifically, the material supply / recycling control unit 98 switches the switching valve 72 so that the material powder being transported by the material recycling conveying device 71 becomes the material recycling bin 70. In addition, the material recycling conveying device 71, the impurity removal device 73, the suction device 74, the material supply bin 76, the material drying device 77, and the material supply conveying device 78 are operated to remove impurities and dry the material powder containing impurities in the material recycling bin 70, and then supply it to the main pipeline 12.

[0228] 2.5. Suction process S1-5

[0229] After the molding process is completed, a suction process S1-5 is performed. In the suction process S1-5, the remaining material on the molding worktable 4 is suctioned using the suction nozzle 79. Specifically, firstly, the work door control unit 92 controls the work door to open. Next, the mobile robot control unit 99 controls the mobile robot 8 to grasp the suction nozzle 79 and move it from the work door into the chamber 1. In addition, during the suction process S1-5, the material recovery device 7 operates in suction mode. The material supply / recovery control unit 98 switches the switching valve 72 so that the material powder transport source using the material recovery conveying device 71 becomes the suction nozzle 79.

[0230] like Figure 16 As shown, during the period from the start to the completion of the modeling process, the modeling worktable 4 descends by a height Hw equivalent to the total thickness of the material layer 81 formed on the base plate 83. In the following description, as... Figure 14 and Figure 16As shown, the position (height) of the modeling worktable 4 in the vertical direction is represented by a single-axis coordinate system with the position of the upper surface of the modeling worktable at the beginning of the modeling process as the origin. Figure 14 The position of the modeling workbench 4 at the start time of the model shown is H=0. Figure 16 The position of the modeling workbench 4 at the completion time of the model shown is H = -Hw.

[0231] like Figure 16 As shown, with the modeling worktable 4 positioned at H = -Hw, the mobile robot control unit 99 controls the mobile robot 8 to move the suction nozzle 79, initiating the suction of remaining material by the suction nozzle 79. During the suction of remaining material, the control device 9 alternately and repeatedly performs the following actions: controlling the worktable drive mechanism 41 via the worktable control unit 95 to raise the modeling worktable 4 by a predetermined rise Δh (rising process S1-5-1); and simultaneously performing the suction of remaining material powder by controlling the mobile robot 8 via the mobile robot control unit 99 to move the suction nozzle 79 according to the teaching data (remaining material suction process S1-5-2).

[0232] An example of this repetitive action will be explained. Before manufacturing the model W, as teaching data, the movement path and posture of the suction nozzle 79 corresponding to the model W are obtained for each rise Δh of the modeling worktable 4. For example, when Δh = 50mm, the movement path and posture of the modeling worktable 4 in the state of position H = -Hw (action pattern P1), the movement path and posture of the modeling worktable 4 in the state of position H = -Hw + 50mm (action pattern P2), the movement path and posture of the modeling worktable 4 in the state of position H = -Hw + 100mm (action pattern P3), the movement path and posture of the modeling worktable 4 in the state of position H = -Hw + 150mm (action pattern P4), etc., are obtained as action patterns P1, action pattern P2, action pattern P3, action pattern P4, ..., action pattern Pn.

[0233] The mobile robot control unit 99 first performs the first residual material suction process S1-5-2 with the molding worktable 4 in position H = -Hw. Specifically, the mobile robot 8 is controlled to move the suction nozzle 79 according to the action pattern P1, suctioning the remaining material from the upper surface of the residual material layer 81a. At the point when the movement under the action pattern P1 is completed, the mobile robot control unit 99 outputs a completion signal to the numerical control unit 91.

[0234] When the numerical control unit 91 receives a completion signal, it outputs an action command to the worktable control unit 95 to raise the modeling worktable 4. In the first raising process S1-5-1, the worktable control unit 95 controls the worktable drive mechanism 41 to raise the modeling worktable 4 to position H = -Hw + 50mm by a rise amount Δh. As a result, the upper surface of the remaining material layer 81a rises. In this state, the second remaining material suction process S1-5-2 is performed. The mobile robot control unit 99 controls the mobile robot 8 to move the suction nozzle 79 according to the action pattern P2, suctioning the remaining material from the upper surface side of the remaining material layer 81a.

[0235] The control device 9 alternately and repeatedly performs the rising process S1-5-1 and the remaining material suction process S1-5-2 until the molding worktable 4 reaches position H=0.

[0236] The teaching data is obtained by recording the position and posture of the suction nozzle 79 while manually operating the mobile robot 8 to move the suction nozzle 79 and suctioning out the remaining material. It represents the appropriate movement path and posture of the suction nozzle 79 corresponding to the shape of the model W and the height of the modeling worktable 4. By suctioning out the remaining material while moving the suction nozzle 79 according to the teaching data, the remaining material can be removed more reliably and efficiently.

[0237] In the suction process S1-5, the rising amount Δh of the molding worktable 4 during one upward movement is preferably 20mm to 80mm, more preferably 35mm to 65mm, for example, 50mm. If the rising amount in one upward movement is too small, the upward movements may be frequent, reducing the efficiency of the suction process S1-5. On the other hand, if the rising amount is too large, the height of the upper surface of the remaining material layer 81a may sometimes exceed the upper end of the powder holding wall 42, making it impossible to hold it on the molding worktable 4.

[0238] In this embodiment, the control device 9 uses the image acquired by the camera device 18 to determine whether there is any remaining material powder. Specifically, as described above, a cleaning image is acquired in advance during the experimental modeling process. In the suction process S1-5, after suction is completed under the various action patterns P1, P2, P3, P4, ... Pn performed by the suction nozzle 79, and the modeling worktable 4 is raised to position H=0, a determination image is acquired by the camera device 18. The image processing device 90c analyzes the cleaning image and the determination image. The numerical control unit 91 of the control device 9 compares these analyzed data to determine whether there is any remaining material in the camera area.

[0239] As an example, the number of pixels or units marked as containing material powder through binarization processing is counted in the analysis data of the clean image and the judgment image. Furthermore, if the difference (Nj-Nc) between the count Nc in the analysis data of the clean image and the count Nj in the analysis data of the judgment image is less than a predetermined value, it is determined that all remaining material has been sucked up. On the other hand, if the difference (Nj-Nc) is greater than a predetermined value, it is determined that remaining material remains in the imaging area, and suction is performed again using the suction nozzle 79. During re-suction, the suction nozzle 79 can move with the final motion pattern Pn of the rising molding table 4, or it can move with the re-suction motion pattern acquired as teaching data.

[0240] Thus, by determining whether there is any remaining material based on the acquired image obtained by the camera device 18, it is possible to reliably remove any remaining material in the camera area, including the base plate 83 and the model W. In particular, even when the base plate 83 and the model W are relatively large, or when the suction of the suction nozzle 79 is applied over a large area due to the suction of remaining material in the area outside the modeling area R, it is possible to determine whether there is any remaining material and remove it reliably.

[0241] Furthermore, the control device 9 of this embodiment determines whether there is any remaining material powder based on the detection results of the detection component. Specifically, at the point when the proportion of material powder in the object being suctioned by the suction nozzle 79 is approximately 0, it is determined that all remaining material in the imaging area has been suctioned.

[0242] In determining whether there is residual material in the small grooves or other details of the object W based on the image acquired by the camera device 18, the accuracy of the determination may decrease depending on the type of material powder or the lighting conditions inside the chamber 1. In such cases, the determination can be made using the detection results from the detection component.

[0243] The determination of the presence or absence of residual material based on the image acquired by the camera device 18 and the determination of the presence or absence of residual material based on the detection result of the detection component can be performed individually, but preferably both are used. By using both methods, the former, which can make a wide-range determination, and the latter, which can make a determination of detailed parts such as the groove and is not easily affected by the type of material powder or lighting, can make a determination with high precision and remove residual material more reliably.

[0244] Furthermore, during the movement of the suction nozzle 79, actions such as stopping the suction action or correcting the movement path can be taken based on the detection results of the torque sensor 8c. When the suction nozzle 79 contacts the model W or the base plate 83, the torque acting on the joint of the robotic arm 8a increases. If the detected torque value is high, damage to the model W can be avoided, for example, by temporarily stopping the suction action or correcting the movement path by moving the suction nozzle 79 away from the model W or the base plate 83.

[0245] After suction is completed, the mobile robot control unit 99 controls the mobile robot 8 to move the suction nozzle 79 from the working door to the outside of the chamber 1 and store it in the storage unit. Thus, the suction process S1-5 ends.

[0246] 2.6. Removal process S1-6

[0247] After the suction process S1-5 is completed, the removal process S1-6 is performed to remove the base plate 83 and the molded object W on the base plate 83 from the chamber 1. Specifically, firstly, the chuck control unit 96 controls the clamping unit 52 of the chuck device 5 to engage / disengage the ball bearing 52d from the locking part 87b, thereby releasing the fixation of the base plate 83 by the chuck device 5. Next, the transfer robot control unit 97 controls the transfer robot 6 to remove the base plate 83 and the molded object W from the mounting plate 84, tray 85, shaft 87, outer cover 54, and chamber 1.

[0248] After the model W is removed from chamber 1, the transfer robot control unit 97 can also control the transfer robot 6 to reverse the model W in the vertical direction to allow the remaining material to fall, or to place the reversed model W on the finishing device for finishing and removal of the remaining material. Furthermore, in the case of secondary processing, after the transfer robot control unit 97 controls the transfer robot 6 to move the model W to the secondary processing device, secondary processing steps S1-7 are performed. In this case, by introducing a fixing device with the same structure as the chuck device 5 into the secondary processing device, the transfer robot 6 can be controlled. Similar to the fixing of the chuck device 5 in the placement step S1-1, the base plate 83 and the model W are fixed and positioned on the fixing device via the mounting plate 84 and the tray 85. This enables automated placement of the model W in the secondary processing device and ensures the same placement accuracy as in the modeling area R, allowing for high-precision secondary processing.

[0249] After the removal process S1-6 is completed, the three-dimensional model W is manufactured sequentially by repeating the above process. In this structure, after the modeling is completed, the remaining material is automatically removed by the suction nozzle 79, thus enabling unmanned removal of the model W from the chamber 1.

[0250] 3. Methods for obtaining teaching data

[0251] Next, the teaching method for acquiring teaching data will be described. The teaching method of this embodiment includes: a placement step S2-1, a material supply step S2-2, a modeling step S2-3, a recording step S2-4, and a lifting step S2-5. The acquisition of teaching data obtained by the teaching method is performed before manufacturing the model W (for example, in a trial modeling). Hereinafter, the case of acquiring teaching data using a stacked modeling apparatus 100 will be described as an example; other stacked modeling apparatuses can also be used.

[0252] In the placement step S2-1, the base plate 83 is fixed in place by means of the chuck device 5 disposed on the molding worktable 4, and the base plate 83 is placed on the molding worktable 4 in the area that forms the molded object W, namely the molding area R. The placement step S2-1 is performed in the same way as the placement step S1-1 in the manufacturing method of the molded object W.

[0253] In the material supply process S2-2, material powder is supplied to and contained in the material receiving section 22a of the material layer forming apparatus 2. The material supply process S2-2 is performed in the same manner as the material supply process S1-2 in the method for manufacturing the model W.

[0254] In the modeling process S2-3, the material layer forming process S2-3-1, which involves supplying material powder to the base plate 83 to form a material layer 81, and the curing process S2-3-2, which involves irradiating a predetermined irradiation area of ​​the material layer 81 with a laser B or an electron beam, are repeatedly performed. This process stacks the curing layers 82 to create a three-dimensional model. The material layer forming process S2-3-1 and the curing process S2-3-2 are performed in the same manner as the material layer forming process S1-3 and the curing process S1-3-2 in the curing layer forming process S1-3 of the method for manufacturing the model W.

[0255] After the shaping process in step S2-3 is completed, the recording process S2-4 and the lifting process S2-5 are performed. In the recording process S2-4, while the operator manually operates the mobile robot 8 to move the suction nozzle 79, the remaining material powder on the shaping worktable 4 is suctioned. The position coordinates and posture of the suction nozzle 79 at this time are transmitted to the control device 9 and recorded.

[0256] Specifically, after the modeling is completed, with the modeling worktable 4 in a position of H = -Hw, the mobile robot 8 is manually operated to move the suction nozzle 79, sucking up the remaining material from the upper surface of the remaining material layer 81a. At this time, the position and posture of the suction nozzle 79 are adjusted so that it does not contact the model W or the base plate 83, and can efficiently suck up the remaining material present in the recesses of the model W. Simultaneously, the suction nozzle 79 is moved until the remaining material to a predetermined depth Δd is removed from the upper surface of the remaining material layer 81a. The depth Δd is set to be equal to the rise Δh of the modeling worktable 4. The position coordinates and posture of the suction nozzle 79 during this movement are recorded at multiple points as motion pattern P1. Furthermore, the movement path of the suction nozzle 79 between points can be, for example, a straight line connecting the two points (linear interpolation), or it can be created based on the shape data of the desired three-dimensional model W.

[0257] After removing the remaining material at depth Δd in the first recording step S2-4, the modeling worktable 4 is raised by a predetermined amount Δh in the rising step S2-5. This raises the upper surface of the remaining material layer 81a. In this state, the second recording step S2-4 is performed. Similar to the first step, the moving robot 8 is manually operated to move the suction nozzle 79, sucking up the remaining material at depth Δd from the upper surface side. The position coordinates and posture of the moving suction nozzle 79 are recorded at multiple points as motion pattern P2.

[0258] Repeatedly perform recording steps S2-4 and rising steps S2-5 until the modeling worktable 4 reaches position H=0 and the remaining material is completely sucked up. This process yields teaching data containing the movement path and posture of the suction nozzle 79 corresponding to the height of the modeling object W and the modeling worktable 4, which are then used as motion patterns P1, P2, P3, P4, ..., Pn. Thus, appropriate teaching data containing the movement path and posture of the suction nozzle 79 corresponding to the shape of the modeling object W and the height of the modeling worktable 4 can be obtained.

[0259] Thus, the movement of the suction nozzle 79, based on the motion pattern obtained through the manual operation of the mobile robot 8, is particularly significant in the suction and removal of residual materials, etc., when the molding worktable 4 is in its highest position (position H=0). By moving the suction nozzle 79 with an appropriate movement path and posture when the molding worktable 4 is in its highest position, not only can the situation of residual materials, etc., remaining on the molding worktable 4 and causing adverse effects on the next molding be avoided, but also residual materials, etc., scattered to the outside of the molding area R can be removed efficiently. Therefore, the cleaning operation in the chamber 1 for maintenance purposes can be automated.

[0260] The number of points in a single motion pattern can be appropriately set according to the size or shape of the model W and the modeling worktable 4, for example, 5 to 40, preferably 10 to 20. If the number of points is too small, the removal efficiency of residual material may decrease or the contact with the model W or the base plate 83 may increase when the suction nozzle 79 is moved based on the teaching data. If the number of points is too large, the control of the mobile robot 8 may become complicated.

[0261] In addition, in the recording process S2-4, besides recording the position coordinates and posture of the suction nozzle 79, the detection results of the torque sensor 8c can also be recorded. By removing data from points with large torque values ​​from the recorded position coordinates and postures, motion patterns with less contact with the model W or the base plate 83 can be created.

[0262] 4. Other implementation methods

[0263] The present invention can also be implemented in the following ways.

[0264] In the described embodiment, the model W is shaped during the experimental modeling process to obtain a clean image, and the model W is also shaped in the modeling steps S2-3 of the teaching method, but this structure is not limited to this. For example, clean images and teaching data can be obtained for multiple models of different sizes, and the clean images and teaching data of the model with the closest size among these multiple models can also be used when manufacturing the model W. In this structure, it is only necessary to obtain clean images and teaching data for a few models with representative sizes, and it is not necessary to obtain clean images and teaching data for each model W.

[0265] The foregoing has described various embodiments of the present invention, but these are merely examples and are not intended to limit the scope of the invention. The novel embodiments described can be implemented in various other ways, with various omissions, substitutions, and modifications made without departing from the spirit of the invention. These embodiments and their variations are included within the scope or spirit of the invention, and are also included within the scope of the invention as set forth in the claims and its equivalents.

Claims

1. A layered modeling device, comprising: The modeling device includes a modeling worktable, a chamber, a material layer forming apparatus, a chuck apparatus, a material recovery apparatus, a transport robot, a mobile robot, and a control device. The modeling worktable is configured to move up and down via a worktable drive mechanism. The chamber covers the area on the modeling worktable where the modeled objects are formed, which is the modeling area. The material layer forming apparatus supplies material powder to a base plate placed in the molding area to form a material layer. The chuck device is disposed on the molding worktable, and is configured to allow the base plate to be easily mounted and detached and fixed within the molding area. The material recovery device includes a suction nozzle capable of sucking up the remaining material powder on the molding worktable. The transport robot is configured to remove the base plate and the shaped object formed on the base plate from the cavity. The mobile robot is configured to move the suction nozzle. The control device alternately and repeatedly controls the workbench drive mechanism to raise the modeling workbench by a predetermined amount, and simultaneously controls the mobile robot according to the teaching data to move the suction nozzle while suctioning the remaining material powder. The teaching data includes the movement path and posture of the suction nozzle corresponding to the shape of the model and the height of the modeling workbench.

2. The layered modeling device according to claim 1, comprising a camera device, The camera device is configured to acquire images of at least the area including the base plate and the shape. The control device uses the image acquired by the camera device to determine whether there is any remaining material powder.

3. The stacking molding apparatus according to claim 1 or 2, comprising a detection component, The detection component is capable of detecting the proportion of the material powder in the material being aspirated by the suction nozzle. The control device determines whether there is any remaining material powder based on the proportion of the material powder.

4. The layered molding device according to claim 3, wherein, The detection component is a flow sensor.

5. The layered molding apparatus according to claim 1 or 2, comprising: A powder holding wall surrounds the molding worktable and is configured to hold the material powder on the molding worktable; as well as The material recycling bin is configured to contain any remaining material powder that has been discharged to the outside of the powder holding wall. The material recovery device includes a recovery mode and a suction mode as its operating modes. The control device is configured to switch the operating mode. The material recycling device is configured such that, in the recycling mode, the material powder in the material recycling bin is recycled, and after removing impurities, the material powder is supplied to the material layer forming device; in the suction mode, the mobile robot moves the suction nozzle, and the suction nozzle is used to suction the remaining material powder on the molding worktable, and removes impurities from the material powder.

6. The layering molding apparatus according to claim 1 or 2, wherein, The sides of the chuck device are covered by a chuck cover. The chuck cover includes an outer cover and an inner cover. The outer cover covers at least a portion of the side surface of the inner cover. The inner cover covers the side of the chuck assembly.

7. The layered molding apparatus according to claim 1 or 2, wherein, The chuck device secures the base plate via a mounting plate.

8. The layered molding apparatus according to claim 7, comprising: The tray, and the shaft mounted on the bottom surface of the tray in a downward-projecting manner. The mounting plate is fixed to the tray. The chuck device is configured to hold the shaft.

9. The layered molding apparatus according to claim 8, wherein, The chuck device includes a chuck base disposed on the molding worktable and a cylindrical clamping unit disposed on the chuck base. The shaft has an annular recess. The clamping unit has an insertion hole into which the shaft can be inserted, and a plurality of balls that can engage with the recess.

10. The layered molding apparatus according to claim 9, wherein, The chuck assembly includes a cylindrical inner cover fixed to the chuck assembly and covering the clamping unit, and a cylindrical outer cover that contacts the bottom surface of the tray and covers at least the upper part of the inner cover.

11. The stacking molding apparatus according to claim 1 or 2, wherein, The suction nozzle includes a suction section on its front end side. The suction section has a cylindrical shape formed by cutting off the end face of the front end with an inclined surface. An opening is provided on the inclined surface.

12. The layering molding apparatus according to claim 1 or 2, wherein, The mobile robot includes a robotic arm and a robotic hand located at the front end of the robotic arm and holding the suction nozzle.

13. The layering molding apparatus according to claim 12, wherein, The mobile robot includes a torque sensor capable of detecting the torque acting on the joints of the robotic arm, and the torque detection result obtained by the torque sensor is output to the control device.

14. The stacking molding apparatus according to claim 1 or 2, wherein, The transport robot is configured to move the base plate into the chamber.

15. The layering molding apparatus according to claim 1 or 2, wherein, The transport robot is configured to invert the object after removing it from the chamber.

16. The stacking molding apparatus according to claim 1 or 2, comprising: A working door located in the chamber and controlled by the control device to be opened and closed.

17. The layering molding apparatus according to claim 16, wherein, When the transport robot moves the base plate into the chamber or removes the base plate from the chamber, the control device opens the operating door.

18. The layering molding apparatus according to claim 16, wherein, The control device controls the mobile robot to grasp the suction nozzle and move it from the working door into the chamber.

19. A manufacturing method for a three-dimensional model, comprising: The process includes the placement process, the curing layer formation process, the suction process, and the removal process. In the loading process, the base plate is fixed in place by means of a chuck device configured on the molding worktable, and the base plate is placed on the molding worktable in the area where the shaped object is formed, i.e., the molding area. In the curing layer forming process, a material layer forming process is repeatedly performed, which involves supplying material powder to the substrate to form a material layer, and a curing process is performed, which involves irradiating a predetermined area of ​​the material layer with a laser or electron beam to form a curing layer, thereby stacking the curing layers. In the suction process, the molding worktable is raised by a predetermined amount using the worktable drive mechanism, and the remaining material powder is suctioned out simultaneously using a mobile robot to move the suction nozzle according to the teaching data. In the removal process, a transfer robot is used to remove the base plate and the shaped object formed on the base plate from the chamber covering the shaped area. The teaching data includes the movement path and posture of the suction nozzle corresponding to the shape of the model and the height of the modeling workbench.

20. A teaching method for acquiring teaching data used when suctioning residual material powder generated during the layering of a three-dimensional model using a suction nozzle, the teaching method comprising: The processes include placement, shaping, recording, and lifting. In the loading process, the base plate is easily fixed by using a chuck device configured on the molding worktable, and the base plate is placed on the molding area, i.e., the area for forming the object, set on the molding worktable. In the modeling process, a material layer forming process is repeatedly performed, which involves supplying material powder to the base plate to form a material layer, and a curing process is performed, which involves irradiating a predetermined area of ​​the material layer with a laser or electron beam to form a curing layer. By stacking the curing layers, a three-dimensional object is formed. During the recording process, while the suction nozzle is moved by manual operation of the mobile robot, the remaining material powder on the molding worktable is suctioned out, and the position coordinates and posture of the suction nozzle are recorded. In the lifting process, the modeling worktable is raised by a predetermined amount. By repeatedly performing the recording process and the rising process, teaching data is obtained, which includes the movement path and posture of the suction nozzle corresponding to the shape of the object and the height of the modeling workbench.

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